Wire-piercing light-emitting diode illumination assemblies

ABSTRACT

A wire-piercing light-emitting diode (LED) a lead frame having a first lead and a second lead. The first lead has a first transition portion and a first bottom portion with a first cutting member, and the second lead having a second transition portion and a second bottom portion with a second cutting member.

RELATED APPLICATION

This application is a continuation of application Ser. No. 13/042,171filed Mar. 7, 2011, which claims the benefit of U.S. ProvisionalApplication No. 61/310,994 filed Mar. 5, 2010, each of which is herebyfully incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to light-emitting diode lamps.More particularly, the present invention relates to a light-emittingdiode lamp that includes a lead frame for piercing portions of a wire tomake consistent contact with a conductor of the wire.

BACKGROUND OF THE INVENTION

Light-emitting diode (LED) lamps provide a source of illumination for avariety of lighting applications, including decorative lighting,automotive lighting, architectural lighting, and other suchapplications. Depending on the particular application, LED chips may bepackaged in a number of different ways to form the LED lamp. However,most conventional LED lamps are formed of an LED chip mounted to alead-frame structure and encapsulated in an epoxy resin lens.

Conventional lead frames include a pair of leads, or electrodes, one toserve as the anode, the other as the cathode. An LED chip is mounted tothe upper portion of the cathode, and a wire bond forms an electricalconnection between the LED chip and the upper portion of the anode. Whena proper voltage is applied to the electrode pair, current flows throughthe LED, and light is produced.

Such conventional lead frames are formed by a mechanical stampingprocess, with the lower portion of the leads consisting of narrowmetallic strips which, when mounted in the LED lamp projectperpendicularly away from the lens. Such leads may have a square orrectangular cross-section such that they form a post-like. This type oflead works well when the LED lamp is to be inserted into a circuit boardor connected to a panel-like support structure.

However, for those applications requiring that the LED leads be coupledto an insulated conductor, such as a decorative light string, ratherthan, for example, a trace on a printed circuit board, connecting theleads of conventional LED lead frames to wiring poses significantchallenges. In some cases, the leads may be soldered directly ends ofthe conductor to form a connection. In other cases, intermediatestructures, such as wire terminals, or mechanical connectors, may beused. In any case, it can be difficult to make such connections, withthe result being unreliable and inconsistent electrical and mechanicalconnection between the lead frame and the wiring. Such difficultiesdrive up the cost of manufacture, and potentially decrease the safety ofthe lighting product.

SUMMARY OF THE INVENTION

Various embodiments of the present invention are directed towire-piercing light-emitting diode (LED) lead frames, lamps,illumination assemblies and decorative light strings, as well as methodsrelated to using and manufacturing same.

In an embodiment, the present invention includes an LED lead frame forpiercing wires having conductors surrounded by insulating material,thereby making electrical contact between the lead frame and the wires.The LED lead frame includes a first lead including a top portion thatreceives an LED and a bottom portion having at least one cutting memberfor piercing a first wire. The lead frame also includes a second leadincluding a top portion and a bottom portion with at least one cuttingmember for piercing a second wire. Further, the first lead and thesecond lead are spaced apart by a predetermined distance.

In another embodiment, the present invention comprises an LED lead framethat includes a first lead including a first transition portion forminga first shoulder, a first pair of cutting members, and defining a firstwire-receiving recess, the first shoulder extending outward and awayfrom the first pair of cutting members; and a second lead including asecond transition portion forming a second shoulder, a second pair ofcutting members, and defining a second wire-receiving recess, the secondshoulder extending outward and away from the second pair of cuttingmembers.

In yet another embodiment, the present invention comprises an LED leadframe that includes a first lead including a top portion and a bottomportion, the bottom portion having a cutting member for piercing a firstwire, the cutting member defining a first wire-receiving channel, and asecond lead including a top portion having a surface supporting an LEDchip carrier and defining a horizontal plane, and a bottom portion, thebottom portion having at least one cutting member for piercing a secondwire, the cutting member defining a second wire-receiving channel. Thebottom portion of the first lead and the bottom portion of the secondlead are coplanar and substantially perpendicular to the horizontalplane supporting the chip carrier.

In an embodiment, the present invention also includes a method ofmanufacturing a wire-piercing lead frame having first and second leads.The method includes forming a light-emitting diode chip carrier on a topsurface of a lead-frame carrier, the lead frame carrier comprising aplanar strip of conductive material; stamping out a first portion of thelead frame carrier to form a first lead of a wire-piercing lead frame,the first lead including a first cutting member, the first cuttingmember attached to the lead frame carrier at an end of the first cuttingmember; stamping out a second portion of the lead frame carrier to forma second lead of a wire-piercing lead frame, the first lead includingthe LED chip carrier at a top portion and a first cutting member at abottom portion, the second cutting member attached to the lead framecarrier at an end of the second cutting member; separating the firstlead and the second lead from the lead-frame carrier, thereby forming anLED lead frame having a first lead and a second lead.

In another embodiment, the present invention includes a method ofmanufacturing a wire-piercing lead frame that includes stamping out afirst portion of a lead frame carrier to form a first lead of awire-piercing lead frame, the first lead including a top portion and abottom portion; stamping out a second portion of the lead frame carrierto form a second lead of a wire-piercing lead frame, the first leadincluding a top portion and a bottom portion, the top portion having anLED chip carrier, and wherein the top portion of the second lead isadjacent the top portion of the first lead; bending the first lead suchthat the top portion is substantially perpendicular to the bottomportion of the first lead; and bending the second lead such that the topportion is substantially perpendicular to the bottom portion of thesecond lead and the top portion of the second lead is coplanar to thetop portion of the first lead.

In another embodiment, the present invention comprises an LED lamp forpiercing insulated wires of a lighting device so as to make electricalcontact between the lamp and the wires of the lighting device. The LEDlamp includes a light-emitting diode lead frame including a conductivefirst lead and a conductive second lead, the first lead having a firstcutting member; a light-emitting diode mounted to the lead frame, thelight-emitting diode electrically connected to the first lead andelectrically connected the second lead; and a lens adjacent thelight-emitting diode and covering at least a portion of the first leadand a portion of the second lead so as to fix a position of the portionof the first lead relative to the portion of the second lead.

In another embodiment of an LED lamp, the first lead further includes atop portion, a middle portion, and a bottom portion, the bottom portioncomprising the cutting member, and the second lead further including atop portion, a middle portion, and a bottom portion, the bottom portioncomprising a cutting member, and wherein the middle portion of the firstlead and the bottom portion of the first lead project away from a centerof the light-emitting diode lead frame in a forward direction such thata distance from the middle portion of the first lead to the center ofthe light-emitting diode lead frame defines a first offset, and whereinthe middle portion of the second lead and the bottom portion of thesecond lead project away from the center of the LED lead frame in arearward direction such that a distance from the middle portion of thesecond lead to the center of the LED lead frame defines a second offset.

In another embodiment, the present invention comprises an LED lamp thatincludes a first lead including a first transition portion forming afirst shoulder, a first pair of cutting members, and defining a firstwire-receiving recess, the first shoulder extending outward and awayfrom the first pair of cutting members; a second lead including a secondtransition portion forming a second shoulder, a second pair of cuttingmembers, and defining a second wire-receiving recess, the secondshoulder extending outward and away from the second pair of cuttingmembers; a light-emitting diode supported by the first lead andelectrically coupled to the first lead and the second lead; and a lensencapsulating the light-emitting diode and a portion of each of thefirst lead and the second lead, whereby the lens maintains a position ofthe first lead relative to the second lead.

In another embodiment, the present invention includes a method ofmanufacturing an LED lamp having a wire-piercing lead frame. The methodincludes the steps of: stamping out a first portion of the lead framecarrier to form a first lead of a wire-piercing lead frame, the firstlead including a first cutting member; stamping out a second portion ofthe lead frame carrier to form a second lead of a wire-piercing leadframe, the second lead including a second cutting member; attaching anLED to the second lead such that the LED is electrically connected tothe second lead; electrically connecting the LED to the first lead suchthat the first lead is in electrical connection with the second leadthrough the LED; encapsulating top portions of the LED, the first leadand the second lead, thereby fixing the position of the first lead withrespect to the second lead and forming an LED lens; separating the firstlead and the second lead from the lead-frame carrier, thereby forming anLED lamp having a first lead and a second lead.

In another embodiment, the present invention comprises an LEDillumination assembly that includes: a retention housing including a topportion coupled to a bottom portion, the top portion defining an LEDlamp-receiving recess; an LED lamp including a wire-piercing LED leadframe having first and second leads, the LED lamp inserted into the LEDlamp-receiving recess of the top portion; a first wire including aconductor and an insulator, and a second wire including a conductor andan insulator, at least a portion of each of the first wire and thesecond wire located between the top portion and the bottom portion ofthe retention housing. Further, the first lead of the LED lead framepierces at least a portion of the first insulator and the second lead ofthe LED lead frame pierces at least a portion of the second insulator,such that the first LED lead contacts the conductor of the first wireand the second LED lead contacts the conductor of the second wire.

Another embodiment of the present invention comprises an LEDillumination assembly including a wire-piercing LED lamp and a retentionhousing for receiving the LED lamp. The retention housing has a housingtop portion and a housing bottom portion that can be interlocked aroundone or more wires. The retention housing defines a recess for guidingthe LED lamp as it pierces the insulation of the wire and retaining theLED lamp such that the first and second leads remain in contact with thewire conductors. The retention housing can also comprise notches forguiding the first and second cutting members as they pierce theinsulation of the wire and retaining the ends of the cutting members tomaintain the connection between the LED lamp and the wire conductors.According to an embodiment of the present invention, the top and bottomportions of the retention housing can be interlocked over a gap in awire such that the first and second leads of the LED lamp engage theends of the wire on either side of the gap to bridge the gap. Theretention housing can comprise a wire divider that prevents the ends ofthe wire from contacting each other and closing the gap.

In another embodiment, the present invention comprises a single-wire LEDillumination assembly that includes: a housing defining an LEDlamp-receiving recess; an LED lamp including a wire-piercing LED leadframe having a first lead with a first cutting member defining a firstplane and a second lead with a second cutting member defining a secondplane, the LED lamp inserted into the LED lamp-receiving recess of thetop portion; a wire including a forward portion and a rear portion, atleast a portion of the wire retained by the housing, the first wiredefining a gap between the forward portion and the rear portion.Further, the first lead of the LED lead frame pierces an insulator ofthe forward portion of the wire and contacts a conductor of the forwardportion, and the second lead of the LED lead frame pierces an insulatorof the rearward portion of the wire and contacts a conductor of the rearportion, such that the forward portion of the wire is electricallyconnected to the rearward portion of the wire through the LED lamp.

In another embodiment, the present invention includes an LEDillumination assembly that includes: an LED lamp including a lead framehaving a first wire-piercing lead with a first cutting member and asecond wire-piercing lead with a second cutting member; a housingdefining a central recess and a wire channel; and a retainer insertedinto a bottom portion of the central recess of the housing. Further, theLED lamp is inserted into a top portion of the central recess of thehousing and into contact with the retainer such that the first andsecond cutting members extend into the wire channel.

In another embodiment, the present invention comprises a decorativelight string. The decorative light string includes: a first wireincluding a first conductor and a first insulator; a second wireincluding a second conductor and a second insulator; and a plurality ofillumination assemblies electrically connected to the first wire and thesecond wire, each illumination assembly including an LED lamp having awire-piercing lead frame with a first lead and a second lead and an LED.Each first lead of each LED lamp pierces a portion of the firstinsulator to make an electrical connection with the first conductor, andeach second lead of each LED lamp pierces a portion of the secondinsulator to make an electrical connection with the second conductor,thereby causing each of the plurality of LED lamps to be in parallelelectrical connection to the other.

In another embodiment, the present invention comprises a decorativelight string that includes: a first wire including a first insulator anda first conductor; a second wire including a second insulator and asecond conductor; a first illumination assembly including a first LEDlamp having a first lead and a second lead, the first lead piercing aninsulation of the first wire to make an electrical connection with thefirst conductor; a second illumination assembly including a second LEDlamp having a first lead and a second lead, the second lead piercing thesecond insulator to make an electrical connection with the secondconductor. Further, the second lead of the first LED lamp iselectrically connected to the first lead of the second LED lamp suchthat the first LED lamp and the second LED lamp are electricallyconnected in series between the first wire and the second wire.

The above summary of the various representative embodiments of theinvention is not intended to describe each illustrated embodiment orevery implementation of the invention. Rather, the embodiments arechosen and described so that others skilled in the art can appreciateand understand the principles and practices of the invention. Thefigures in the detailed description that follow more particularlyexemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a wire-piercing LED lamp according to anembodiment of the present invention;

FIG. 2 is a front view of the LED lamp of FIG. 1;

FIG. 3 is a right-side view of the LED lamp of FIG. 1;

FIG. 4 is a top view of the LED lamp of FIG. 1;

FIG. 5 is an exploded view of a two-wire LED illumination assemblyaccording to an embodiment of the present invention;

FIG. 6 is a perspective view of the assembled two-wire LED illuminationassembly of FIG. 5;

FIG. 7 is a front view of the LED illumination assembly of FIG. 6;

FIG. 8 is a top view of the LED illumination assembly of FIG. 6;

FIG. 9 is a fragmentary sectional view of the LED illumination assemblyof FIG. 6, with the retention housing removed;

FIG. 10 is an exploded view of a single-wire LED illumination assemblyaccording to an embodiment of the present invention;

FIG. 11 is a perspective view of the assembled single-wire LEDillumination assembly of FIG. 10;

FIG. 12 is a front view of the LED illumination assembly of FIG. 10;

FIG. 13 is a top view of the LED illumination assembly of FIG. 10; and

FIG. 14 is a fragmentary sectional view of the LED illumination assemblyof FIG. 10, with the retention housing removed;

FIG. 15 is an exploded view of a three-wire LED illumination assemblyaccording to an embodiment of the present invention;

FIG. 16 is a front perspective view of the assembled three-wire LEDillumination assembly of FIG. 15;

FIG. 17 is a top view of the three-wire LED illumination assembly ofFIG. 16;

FIG. 18 is a front perspective view of an LED lamp having a Z-shapedlead frame, according to an embodiment of the present invention;

FIG. 19 is a right-side view of the LED lamp of FIG. 18;

FIG. 20 is a front view of the LED lamp of FIG. 18;

FIG. 21 is a top view of the LED lamp of FIG. 18;

FIG. 22 is an exploded perspective view of a two-wire LED illuminationassembly including the LED lamp of FIG. 18, according to an embodimentof the present invention;

FIG. 23 is a front perspective view of the assembled two-wire LEDillumination assembly of FIG. 22;

FIG. 24 is a top view of the two-wire LED illumination assembly of FIG.23;

FIG. 25 is an exploded perspective view of a single-wire LEDillumination assembly including the LED lamp of FIG. 18, according to anembodiment of the present invention;

FIG. 26 is a top view of the assembled single-wire LED illuminationassembly of FIG. 25;

FIG. 27 is an exploded view of a three-wire LED illumination assemblyincluding an LED lamp of FIG. 18, according to an embodiment of thepresent invention;

FIG. 28 is a top view of the assembled three-wire LED illuminationassembly of FIG. 27;

FIG. 29 is a front perspective view of another LED lead frame, accordingto an embodiment of the present invention;

FIG. 30 is a front perspective, exploded view of a two-wire LEDillumination assembly including the LED lead frame of FIG. 29, accordingto an embodiment of the present invention;

FIG. 31 is a top view of the two-wire LED illumination assembly of FIG.30;

FIG. 32 is a front perspective view of yet another LED lead frame,according to an embodiment of the present invention;

FIG. 33 is a front perspective view of another LED lead frame, accordingto an embodiment of the present invention;

FIG. 34 is a front perspective view of another three-wire LEDillumination assembly, according to an embodiment of the presentinvention;

FIG. 35 is a top view of the three-wire LED illumination assembly ofFIG. 34;

FIG. 36 is a front perspective, exploded view of a three-wire LEDillumination assembly having a bypass arrangement, according to anembodiment of the present invention;

FIG. 37 is a front perspective view of the bypass arrangement of thethree-wire LED illumination assembly of FIG. 36;

FIG. 38 is an electrical schematic of the three-wire LED illuminationassembly of FIG. 36;

FIG. 39 is a front perspective, exploded view of a three-wire LEDillumination assembly including an electrical jumper, according to anembodiment of the present invention;

FIG. 40 is a left-side perspective of the three-wire LED illuminationassembly of FIG. 39;

FIG. 41 is a left-side view of the jumper of FIG. 40, according to anembodiment of the present invention;

FIG. 42 is a top view of the jumper of FIG. 41;

FIG. 43 is a front view of the jumper of FIG. 41;

FIG. 44 a is an electrical schematic of the three-wire LED illuminationassembly of FIG. 39;

FIG. 44 b is another electrical schematic of the three-wire LEDillumination assembly of FIG. 39;

FIG. 45 is a left-side perspective view of a three-wire LED illuminationassembly including a jumper and bypass, according to an embodiment ofthe present invention;

FIG. 46 s an electrical schematic of an embodiment of the three-wire LEDillumination assembly of FIG. 45;

FIG. 47 is a front perspective view of an LED lamp having a twisted-leadLED lead frame, according to an invention of the present invention;

FIG. 48 a is a front view of a lead-frame carrier including threelead-frames, according to an embodiment of the present invention;

FIG. 48 b is a left-side view of the lead-frame carrier with lead-framesof FIG. 48 a;

FIG. 48 c is a top view of the lead-frame carrier with lead frames ofFIG. 48 a;

FIG. 49 is an exploded, front perspective view of an LED illuminationassembly, according to an embodiment of the present invention;

FIG. 50 a is a front view of the assembled LED illumination assembly ofFIG. 49;

FIG. 50 b is a top view of the assembled LED illumination assembly ofFIG. 49;

FIG. 50 c is a cross-sectional view of the assembled LED illuminationassembly of FIG. 49;

FIG. 51 a is a front perspective view of an LED illumination assemblyhaving a branch clip, according to an embodiment of the presentinvention;

FIG. 51 b is a top view of the LED illumination assembly of FIG. 51 a;

FIG. 52 a is a front perspective view of an LED illumination assemblyincluding a wire clip, according to an embodiment of the presentinvention;

FIG. 52 b is a top view of a housing bottom portion of the LEDillumination assembly of FIG. 52 a;

FIG. 53 a is an exploded, front perspective view of another LEDillumination assembly, according to an embodiment of the presentinvention;

FIG. 53 b is a front view of the assembled LED illumination assembly ofFIG. 53 a;

FIG. 53 c is a sectional view of the LED illumination assembly of FIG.53 b;

FIG. 54 a is a block diagram and electrical schematic of a two-wire LEDillumination assembly, according to an embodiment of the presentinvention;

FIG. 54 b is a block diagram and electrical schematic of a single-wireLED illumination assembly, according to an embodiment of the presentinvention;

FIG. 54 c is a block diagram and electrical schematic of a three-wireLED illumination assembly, according to an embodiment of the presentinvention;

FIG. 54 d is a block diagram and electrical schematic of a three-wireLED illumination assembly including a jumper, according to an embodimentof the present invention;

FIG. 54 e is a block diagram and electrical schematic of anotherthree-wire LED illumination assembly including a jumper, according to anembodiment of the present invention;

FIG. 55 is a block diagram and electrical schematic of a decorativelight string, according to an embodiment of the present invention; and

FIG. 56 is a block diagram and electrical schematic of anotherdecorative light string, according to an embodiment of the presentinvention.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIGS. 1-4, an embodiment of a light-emitting diode (LED)lamp 100 of the present invention is depicted. LED lamp 100 includeslead frame 102, LED chip 104, lead-chip connector 106, and lens 108. Insome embodiments, LED lamp 100 may also include LED chip carrier 110.

In one embodiment, lead frame 102 includes first lead 112 and secondlead 114, and may be comprised of any known conductive materials,including metallic materials such as aluminum, copper, bronze, tin, orsimilar such conductive materials. First lead 112 and second lead 114are separated such that leads 112 and 114 are not in direct contact witheach other, and such that the leads define side-to-side gap 116. Gap 116may vary along a length of lead frame 102.

First lead 112 includes top portion 118, forward-projecting ledge 120,middle portion 122, transition portion 124, and bottom portion 126.

Top portion 118 may generally be triangular in shape as depicted, thoughit will be understood that top portion 118 may assume other shapes asrequired to meet the particular structural and aesthetic requirements ofLED lamp 100. Top portion 118 extends in a generally downward directionto meet forward-projecting ledge 120. In other embodiments, top portion118 connects to chip carrier 110 at a side portion, and extends in ahorizontal direction before extending downward to meetforward-projecting ledge 120.

Forward-projecting ledge 120 projects away from top portion 118 in agenerally forward direction. As depicted, forward-projecting ledge 120forms a substantially 90° angle with top portion 118, though projectingledge 120 and top portion 118 may form angles other than 90° angles inother embodiments.

Middle portion 122 may generally be rectangular in shape as depicted,though it will be understood that middle portion 122 may assume othershapes as required. Middle portion 122 projects generally downward andaway from forward-projecting ledge 120, such that middle portion 122 andtop portion 118 lie in different planes, and are separated in aforward-to-rearward direction by offset 130.

Referring specifically to FIG. 3, top portion 118 lies in a plane thatincludes axis A-A, while middle portion 122 lies in a plane thatincludes axis B-B. Offset 130 is the distance between planes includingaxis A-A and axis B-B. Offset 130 also defines a length offorward-projecting ledge 120. As discussed further below, offset 130 mayvary to accommodate different lead frames 102 adapted to work withspecific wire and conductor sizes.

As depicted, offset 130 defines a constant distance between planes thatinclude top portion 118 and middle portion 122. However, in otherembodiments wherein top portion 118 and middle portion 122 do not lie inparallel planes, offset 130 may vary such that it is greatest at a pointfurthest from top portion 118 and least at a point closest top portion120.

Referring specifically to FIG. 4, offset 130 is also depicted as thedistance between axis A′-A′ and axis B′-B′, where axis A′-A′ isperpendicular to, and lies in the same plane as, axis A-A, and axisB′-B′ is perpendicular to, and lies in the same plane as, axis B-B.

Referring again to FIGS. 1-4, middle portion 122 transitions to bottomportion 126 at transition portion 124. As depicted, transition portion124 forms a shoulder or step and includes transition surface 132.Transition surface 132 may be planar, and generally parallel to a planeformed by forward-projecting ledge 120, and not coplanar to bottomportion 126. However, in other embodiments, wherein transition portion124 comprises other transition features, transition surface 132 may liein a plane not parallel to a plane formed by ledge 120. In one suchembodiment, middle portion 122 is substantially the same thickness asbottom portion 126, and transition surface 132 is substantially planarwith both middle portion 124 and bottom portion 126.

In the embodiment depicted, bottom portion 126 includes front surface127, rear surface 129, and cutting members 134 a and 134 b. Bottomportion 126 defines conductor receiving recess 137. Cutting members 134a and 134 b include cutting edges 136 a and 136 b, respectively. Asdepicted, cutting edges 136 a and 136 b angle inwards and towardswire-receiving recess 137. In other embodiments, cutting edges 136 a and136 b may angle more or less steeply towards conductor-recess 137. Inother embodiments, bottom portion 126 may include only a single cuttingmember. In an embodiment, bottom portion 126 is integral to middleportion 122 or top portion 118, rather than forming a separablecomponent.

Wire-receiving recess 137 may be formed by arcuate and linear edgeportions of bottom portion 126 as depicted, but may form other generallysemi-circular, square, slotted, V, or other shapes. As described furtherbelow, an arcuate shaped wire-receiving recess 137 maximizes contactwith conductors of wires while potentially minimizing cutting of theconductor.

Second lead 114 includes top portion 138, rearward-projecting ledge 140,middle portion 142, transition portion 144, and bottom portion 146.

Top portion 138 may generally be triangular in shape as depicted, thoughit will be understood that top portion 138 may assume other shapes asrequired to meet the particular structural and aesthetic requirements ofLED lamp 100. As discussed further below, top portion 138 may beconfigured to receive optional LED chip carrier 110 by including a step,recess, or other appropriate-sized cavity. In other embodiments, topportion 138 may be adapted to receive LED chip 104 mounted directly to atop surface of top portion 138. Top portion 138 extends in a generallydownward direction to meet rearward-projecting ledge 140.

Rearward-projecting ledge 140 projects away from top portion 138 in agenerally rearward direction, and in one embodiment is substantiallysimilar to forward-projecting ledge 120, with the exception of thedirection of projection. As depicted, rearward-projecting ledge 140forms a substantially 90° angle with top portion 138, thoughrearward-projecting ledge 140 and top portion 138 may form angles otherthan 90° angles in other embodiments.

Middle portion 142 in the depicted embodiment is substantially similarto middle portion 122. Middle portion 142 may generally be rectangularin shape as depicted, though it will be understood that middle portion142 may assume other shapes as required. Middle portion 142 projectsgenerally downward and away from rearward-projecting ledge 140, suchthat middle portion 142 and top portion 138 lie in different planes, andare separated in a rearward-to-forward direction by offset 150.

Referring specifically to FIG. 3, top portion 138 lies in a plane thatincludes axis A-A, while middle portion 142 lies in a plane thatincludes axis C-C. Offset 150 is the distance between planes includingaxis A-A and axis C-C. Offset 150 also defines a length ofrearward-projecting ledge 120. As discussed further below, offset 150may vary to accommodate different lead frames 102 adapted to work withspecific wire and conductor sizes.

As depicted, offset 150 defines a constant distance between planes thatinclude top portion 138 and middle portion 142. However, in otherembodiments, wherein top portion 138 and middle portion 142 do not liein parallel planes, offset 150 may vary such that it is greatest at apoint furthest from top portion 138 and least at a point closest topportion 140.

Referring specifically to FIG. 4, offset 150 is also depicted as thedistance between axis A′-A′ and axis C′-C′, where axis A′-A′ isperpendicular to, and lies in the same plane as, axis A-A, and axisC′-C′ is perpendicular to, and lies in the same plane as, axis C-C.

Referring again to FIGS. 1-4, middle portion 142 transitions to bottomportion 146 at transition portion 144. As depicted, transition portion144 may include transition surface 152. In one embodiment, transitionsurface 152 is planar, and generally parallel to a plane formed byforward-projecting ledge 140. However, in other embodiments, whereastransition portion 144 comprises other transition features, transitionsurface 152 may lie in a plane not parallel to a plane formed by ledge140. In one such embodiment, middle portion 142 is substantially thesame thickness as bottom portion 146, and transition surface 152 issubstantially planar with both middle portion 144 and bottom portion146.

In the embodiment depicted, bottom portion 146 is substantially the sameas bottom portion 126. Bottom portion 146 includes front surface 147,rear surface 149, and cutting members 154 a and 154 b. Bottom portion146 defines conductor receiving recess 157. Cutting members 154 a and154 b include cutting edges 156 a and 156 b, respectively. As depicted,cutting edges 156 a and 156 b angle inwards and towards wire-receivingrecess 157. In other embodiments, cutting edges 156 a and 156 b mayangle more or less steeply towards conductor-recess 157.

Wire-receiving recess 157 may be formed by arcuate and linear edgeportions of bottom portion 146 as depicted, but may form other generallysemi-circular, square, slotted, or other shapes.

LED chip 104 may be one or more of any of known light-emitting diodechips or dies. LED chip 104 may comprise one or more light-emittingdiodes and may also comprise other electronic devices within, orwithout, the chip package. LED chip 104 may operate on AC or DC power,and at varying voltages, as will be understood by those skilled in theart. Other electronic devices may include zener diodes, other types ofnon-light-emitting diodes, control circuitry, and so on.

Lead-chip connector 106 forms an electrical connection between LED chip104 and lead 112. In one embodiment, as depicted, lead-chip connector106 comprises wire bonding. In other embodiments, lead-chip connector106 may comprise flip-chip, or other known technology, to form anelectrical connection between LED chip 104 and lead 112.

Lens 108 encapsulates portions of lead frame 102, LED chip 104,connector 106 and carrier 110, and comprises a transparent orsemi-transparent plastic material such as an epoxy resin. Lens 108 maycomprise other similar materials as understood by those skilled in theart. By encapsulating portions of lead frame 102, LED chip 104,connector 106, and carrier 110, lens 108 holds the relative positions ofthese components fixed, including the position of lead 112 to lead 112.Although lens 108 is depicted as comprising a generally cylindricalshape, it will be understood that lens 108 may comprise any of a varietyof known shapes and sizes.

LED lamp 100 may also include optional LED chip carrier 110. Asdepicted, LED chip carrier 110 comprises a bowl-shaped structure thatmay also include a reflective inner surface. It will be understood thatif present, LED chip carrier 110 may comprise other known structures andshapes.

When assembled, LED chip 104 is mounted directly to lead 114, or to LEDchip carrier 110, which is in turn mounted to lead 114. Lead-chipconnector 106 forms an electrical connection between LED chip 104 andlead 112. In this configuration, lead 112 serves as the positiveelectrode, or anode, while lead 114 serves as the negative electrode, orcathode. However, in another embodiment, top portion of lead 112 couldbe adapted to receive LED 104 such that it serves as the cathode, whilelead 114 serves as the anode. Lens 108 holds the assembly together,forming an encapsulation or housing around the other components to formLED lamp 100.

Referring to FIGS. 5-8, LED lamp 100 may be combined with retentionhousing 160 and wires 162 and 164 to form LED illumination assembly 166.LED illumination assembly 166 may comprise a portion of a lightingsystem or string that includes multiple LED illumination assemblies 166.Alternatively, LED illumination assembly 166 may comprise a stand-aloneassembly for providing illumination via a single LED lamp 100.

Referring specifically to FIG. 5, retention housing 160 includes housingtop portion 170 and housing bottom portion 172, and may be constructedof a plastic or polymer material, ceramic, or other such material.

Top portion 170 may be generally cylindrical as depicted, but it will beunderstood that top portion 170 may comprise other shapes. Top portion170 includes outer surface 182 and inner surface 184, and defines firstwire channel or upper groove 186, second upper groove 188, and LED lampreceiving recess 190. Upper ridge 192 is formed between first uppergroove 182 and second upper groove 184.

First upper groove 186 is sized to receive a portion of wire 162, whilesecond upper groove 188 is sized to receive an upper portion of wire164.

Bottom portion 172 may form a disk-like, cap-like, or similar structure,and includes outer surface 194, top surface. Bottom portion 172 definesfirst wire channel or lower groove 196 and second lower groove 198.Lower ridge 200 is formed between first lower groove 196 and secondlower groove 198.

First lower groove 196 is sized to receive a lower portion of wire 162,while second lower groove 198 is sized to receive a lower portion ofwire 164.

Wire 162 includes conductor 202 and insulator 204; wire 164 includesconductor 206 and insulator 208.

Referring also to FIGS. 6-8, when assembled, LED lamp 100 is insertedinto LED lamp-receiving recess 190. Housing top portion 170 is coupledto housing lower portion 172, with wires 162 and 164 between top andbottom portions 170 and 172. Wire 162 is securely received by upper andlower grooves 186 and 196, while wire 164 is securely received by upperand lower grooves 188 and 198. In one embodiment, upper ridge 192contacts upper portions of wires 162 and 164, while lower ridge 200contacts lower portions of wires 162 and 164. In an alternativeembodiment, wires 162 and 164 are spaced apart such that when housingtop portion 170 is joined to housing bottom portion 172, lower ridge 200is in contact with upper ridge 192.

Housing top portion 170 and housing bottom portion 172 may be coupledtogether by any number of methods including, but not limited to, atongue and groove arrangement, interference fit, snap fit, clip fit,adhesive bonding, spin welding, sonic welding, or other such methods forsecurely coupling the two portions together.

In one embodiment, LED lamp 100 may be firstly be inserted into LEDlamp-receiving recess 190 of housing top portion 170. LED lamp 100 maybe secured to top portion 170 by any number of methods including, butnot limited to, pressing LED lamp 100 into housing top portion 170 tocreate an interference fit, with or without the use of an additionalsleeve (not depicted), through the use of adhesive bonding, or othersimilar such methods. In such an embodiment, LED lamp 100 and topportion 170 are assembled to wires 162 and 164, and to housing bottomportion 172, causing leads 112 and 114 to pierce wires 164 and 162,respectively, as will be discussed further below.

In other embodiments, housing top portion 170 may be firstly assembledto wires 162 and 164, followed by the insertion of LED lamp 100, orhousing top portion 170, LED lamp 100, and housing bottom portion 172may be assembled in one step. Regardless of the particular assemblymethod, the result is that housing top and bottom portions 170 and 172are coupled together to securely retain LED lamp 100 which pierces wires162 and 164.

Referring to FIG. 8, a top view of LED illumination assembly 166 isdepicted. In this embodiment, LED lamp 100 is centered above wires 162and 164, while lead frame 102 is generally perpendicular to wires 162and 164. Forward-projecting ledge 120 of lead 112 projects in aforwardly direction such that middle portion 122 and bottom portion 126are offset in a forwardly direction from a center of LED lamp 100.Similarly, rearward-projecting ledge 140 of lead 114 projects in arearwardly direction such that middle portion 142 and bottom portion 146are offset in a rearwardly direction from the center of LED lamp 100.

Referring also to FIG. 9, a fragmentary sectional view of LEDillumination assembly 166, with retention housing 160 removed, isdepicted. The view of FIG. 9 is a sectional through lead 112 in a firstplane, and a sectional through lead 114 through a second plane,depicting the interaction between lead 112 and wire 164, and betweenlead 114 and wire 162.

As discussed briefly above, during assembly, a downward force may beapplied to lead frame 102 such that it is pressed downward onto wires162 and 164. With respect to lead 112, cutting members 134 a and 134 binitially contact a top portion of wire 164 at cutting edges 136 a and136 b. As lead 112 moves in a downwardly direction perpendicular to wire164, cutting edges 136 a and 136 b pierce an outer surface of insulation204, and cut through portions of insulation 204 at a top of wire 164.Wire-receiving recess 137 receives conductor 206 and may receiveportions of insulation 204. As wire-receiving recess 137 receivesconductor 206, some portions of conductor 206 may be channeled, ormoved, along cutting edges 136 a and 136 b into wire-receiving recess137, such that conductor 206 is clenched by bottom portion 126. Otherportions of conductor 206 may be cut by cutting members 134 a and 134 b.Lead 112 stops at a final contact position as depicted in FIG. 9.

This final contact position is determined in part by the interaction oftransition portion 124 and insulator 208. As discussed above, as lead112 moves downward relative to wire 164, cutting members 134 a and 134 bcut through insulator 208 and portions of conductor 206. When transitionportion 124 of lead 112 contacts insulator 208 at transition surface132, bottom portion 126 generally ceases to move relative to wire 162.In other words, transition portion 124, depicted in this embodiment as ashoulder-like structure with a transition surface 132, is not capable ofcutting through insulator 208, providing a counter-force and acting as astopping mechanism.

In some embodiments, a distance from transition portion 124 towire-receiving recess 137, distance “d”, is approximately equal to, orslightly greater than a thickness of insulator 208, such that bottomportion 126 and wire-receiving recess 137 align with conductor 208 formaximum contact. It will be understood that distance d may also begreater than, or less than a thickness of conductor 208 so as to varythe alignment of bottom portion 126 and conductor 128. For example,distance d in an alternate embodiment may be slightly greater than thethickness of insulator 208 to ensure that cutting members 134 a and 134b completely pierce insulator 208 prior to stopping.

In its final contact position, lead 112 has pierced wire 164 andcontacts conductor 206 at front surface 127, rear surface 129, portionsof cutting edges 136 a and 136 b, and along a perimeter ofwire-receiving recess 137. Such contact of metallic lead 112 withconductor 206 provides a reliable conductive pathway for current flowingthrough conductor 206 and LED lamp 100.

In substantially the same manner that lead 112 pierces wire 164, lead114 moves downward onto wire 162, such that cutting edges 156 a and 156b cut through insulator 204 and portions of conductor 202. Lead 112comes to rest at the final contact position after transition surface 152of transition portion 144 contacts insulator 204.

Coupling LED lamp 100 to wires 162 and 164 as described above provides anumber of benefits over the prior art.

Firstly, leads 112 and 114 will consistently contact conductors 206 and202, respectively, in a consistent and repeatable manner, providing areliable electrical connection between LED lamp 100 and wires 162 and164. This not only improves overall quality of any product incorporatingLED lamps 100 or LED illumination assemblies 166, but also increasessafety by reducing the possibility of arcing between conductors andleads.

Secondly, the cost of assembling LED lamps 100 to one or more wires 162or 164 is significantly reduced as the time for assembly is less thanthat of conventional LED lamp and wire assemblies. For lighting stringsemploying high numbers of LED illumination assemblies 166, this time andcost savings may be extremely significant.

As described above, LED lamp 100 may be assembled into LED illuminationassembly 166 having a pair of wires. When multiple assemblies 166 areassembled on a pair of wires 162 and 164, LED lamps 100 are electricallyin parallel to each other. However, it may be advantageous to usemultiple LED lamps 100 to form a lighting string or lighting system inwhich the multiple LED lamps 100 are electrically in series.

Referring to FIGS. 10-14, in an alternate embodiment, LED lamp 100 maybe assembled to a single wire to form LED illumination assembly 210.

LED illumination assembly 210 includes LED lamp 100, retention housing212, and wire 214.

Retention housing 212 is substantially similar to retention housing 160,though retention housing 212 defines a single upper groove, single lowergroove, and includes a wire divider. More specifically, retentionhousing 212 includes housing top portion 216 and housing lower portion218. Housing upper portion defines groove 222 and lamp receiving recess224. Housing lower portion 218 includes wire divider 220 and defineslower groove 226.

Wire divider 220 projects generally upwards and away from housing lowerportion 218 at lower groove 226. In one embodiment, wire divider 220comprises a generally flat, panel-like structure, and is comprised of anon-conductive material such as plastic, or other similar non-conductingmaterials.

Wire 214 includes conductor 228 and insulator 230, and is divided intoforward section 232 and rear section 234. Forward section 232 includesconductor 228 a and insulator 230 b; rear section 234 includes conductor228 b and insulator 230 b. A length of wire 214 extends in a directionparallel to an axis F.

Referring also to FIG. 13, in the embodiment depicted, wire divider 220may be positioned angularly to wire 214. More specifically, an axis Hparallel to a length of wire divider 220 forms an angle α with axis F ofwire 214. Angle α in one embodiment may be approximately 45°. In otherembodiments, angle α may range from 15° to 75°.

A thickness of wire divider 220 is such that it will fit between leads112 and 114 in gap 116. A length of wire divider 220 is such that itwill span the width of wire 214 and grooves 226 and 222.

LED illumination assembly 210 is assembled in substantially the samemanner as LED illumination assembly 166, with the exception of therotation of LED lamp 100, and the piercing of wire segments 232 and 234.

LED lamp 100 is inserted into retainer housing 212 and moved downwardonto wire 214. LED lamp 100 is guided into proper alignment with wire214, in part by wire divider 220, as wire divider 220 is insertedbetween leads 112 and 114.

Wire segments 232 and 234 are received by lower groove 226 and may belocated adjacent to, or near, wire divider 220, such that lead 112 willcontact wire segment 232 and lead 114 will contact wire segment 234.Wire segments 232 and 234 are not electrically connected, and remainseparated by wire divider 220.

Similar to the manner discussed above with respect to LED illuminationassembly 166, as LED lamp 100 is moved downward, cutting members 134 aand 134 b of lead 112 pierce wire segment 232. At the same time, cuttingmembers 154 a and 154 b pierce wire segment 234.

When transition portions 124 and 144 respectively contact segments 232and 234, a final contact position is reached.

FIG. 11 provides a perspective view of LED illumination assembly 210,while FIG. 12 provides a side view of LED illumination assembly 210.

Referring to FIGS. 13 and 14, the final contact position of LED lamp 100with respect to wire 214 is depicted in further detail. Lead frame 102and its leads 112 and 114 contact wire 214 at an angle β as defined bywire axis F and lead frame 102 axis G. As depicted, in one embodiment,angle β may be approximately 45°. In other embodiments, angle β mayrange from 15° to 75°. When angle α and angle β are both 45°, lead frame102 and wire divider 220 are perpendicular to each other and intersectwire 214 at approximately 45° as depicted in FIG. 13.

Referring to FIG. 14, a fragmentary, sectional view of LED illuminationassembly 210 is depicted, with housing 212 removed, and wire 214 shownin phantom lines.

As depicted, leads 112 and 114 each form an approximately 45° angle withwire 214, making electrical contact with their respective wire segments232 and 234. A right-side portion of conductor 228 a of wire segment 232is received by wire-receiving recess 137 and clasped by bottom portion126, while a left-side portion of conductor 228 b of wire segment 232 isreceived by wire-receiving recess 157, and clasped by bottom portion146. Accordingly, lead 112 makes a reliable electrical contact withconductor 228 a, while lead 114 makes a reliable electrical contact withconductor 228 b.

In this single-wire, electrical-series embodiment, when powered, currentflows through conductor 228 a of wire segment 232 through lead 112 andLED chip 104, and out lead 114 and conductor 228 b of wire segment 234.As such, a plurality of LED illumination assemblies 210 may be connectedtogether to form a series-connected lighting string or system.

Referring to FIGS. 15-17, in another embodiment, LED lamp 100 may beassembled to three wires to form an LED illumination assembly 300.

LED illumination assembly 300 includes LED lamp 100, retention housing302, right wire 304, middle wire 306, and left wire 308.

Retention housing 302 is substantially similar to retention housings 160and 212, though retention housing 302 defines three upper grooves, andthree lower grooves, and includes a single wire divider. Morespecifically, retention housing 302 includes housing upper portion 310and housing lower portion 312. Housing upper portion 310 defines rightgroove 314, middle groove 316, left groove 318, and lamp receivingrecess 322. Housing lower portion 312 includes wire divider 324 anddefines right groove 326, middle groove 328, and left groove 330.

Wire divider 324 is substantially similar to wire divider 220, andprojects generally upwards and away from housing lower portion 312 atmiddle groove 328. In one embodiment, wire divider 324 comprises agenerally flat, panel-like structure, and is comprised of anon-conductive material such as plastic, or other similar non-conductingmaterials.

Right wire 304 includes conductor 332 and insulator 334; middle wire 306includes conductor 336 and insulator 338; and left wire 308 includesconductor 340 and insulator 342. Middle wire 306 is divided into forwardsection 344 and rear section 346.

In this triple-wire embodiment, LED illumination assembly 300, lamp 100and lead frame 102 pierce middle wire 306 in substantially the samemanner as lamp 100 and lead frame 102 pierce wire 214 in LEDillumination assembly 210. Lead 112 pierces forward section 344, whilelead 114 pierces rear section 416, such that a series electricalconnection may be made.

As depicted, right wire 304 and left wire 308 are generally not piercedby lamp 100 or lead frame 102. In some embodiments, not depicted, leadframe 102 may incidentally pierce a portion of wires 304 and/or 308.Wires 304 and 308 may be used when a plurality of LED illuminationassemblies are connected together to form a lighting string.

Referring to FIGS. 18-21, another embodiment of the present invention,LED lamp 350 with wire-piercing lead frame 352 is depicted. LED lamp 350includes lead frame 352, LED chip 104, lead-chip connector 106, and lens108. In some embodiments, LED lamp 350 may also include LED chip carrier110.

Lead frame 352 includes first lead 354 and second lead 356, and similarto lead frame 102, may be comprised of any known conductive materials,including metallic materials such as aluminum, copper, bronze, tin, orsimilar such conductive materials.

First lead 354 includes top portion 358, connecting portion 360, and endportion 362. End portion 362 includes upper portion 364, transitionportion 366, and bottom portion 368.

Top portion 358 may be substantially similar to top portion 118. Topportion 358 joins with connecting portion 360, which in turns joins endportion 362. Connecting portion may be generally curved as depicted, butin other embodiments may form a corner or other connection structure.End portion 362 extends perpendicularly and downwardly away fromconnecting portion 362.

Upper portion 364 of end portion 362 may be generally rectangular asdepicted, though in other embodiments may be cylindrical, or compriseother shapes. Transition portion 366 is substantially similar totransition portion 124, and includes surface 370. Bottom portion 368 maybe substantially similar to bottom portion 126, and includes frontsurface 372, rear surface 374, and cutting members 376 a and 376 b.Bottom portion 368 defines conductor receiving recess 378. Cuttingmembers 376 a and 376 b include cutting edges 380 a and 380 b,respectively.

Second lead 382 includes top portion 384, connecting portion 386, andend portion 388. End portion 388 includes upper portion 390, transitionportion 392, and bottom portion 394.

Top portion 384 may be substantially similar to top portion 138. Topportion 384 joins with connecting portion 386, which in turns joins endportion 388. End portion 388 extends perpendicularly and downwardly awayfrom connecting portion 386.

Upper portion 390 of end portion 362 may be generally rectangular asdepicted, though in other embodiments may be cylindrical, or compriseother shapes. Transition portion 392 may be substantially similar totransition portion 144, and includes surface 396. Bottom portion 394 maybe substantially similar to bottom portion 146, and includes frontsurface 400, rear surface 402, and cutting members 404 a and 404 b.Bottom portion 394 defines conductor receiving recess 406. Cuttingmembers 404 a and 404 b include cutting edges 408 a and 408 b,respectively.

Referring specifically to FIG. 21, as depicted in a top view of LED lamp350, in this embodiment, lead frame 352 forms a “Z” or backward “Z”shape, with top portion 358 having a longitudinal axis I forming anangle ⊖ with end portion 362 having a longitudinal axis J. In theembodiment depicted, angle ⊖ is approximately 45°. However, in otherembodiments, angle ⊖ may range from 0° to 360°. Modifying angle ⊖determines, in part, an angle at which bottom portion 394 pierces awire, as discussed further below.

Similarly, top portion 384 sharing the longitudinal axis I forms anangle Φ with end portion 388 having a longitudinal axis K. In theembodiment depicted, angle Φ is approximately 45°. However, in otherembodiments, angle Φ may range from 0° to 360°. Further, angle Φ may bedifferent in magnitude than angle ⊖.

Leads 352 and 354 are separated by a distance 410 which may varydepending on wire size and other application-specific factors. Lamp 350with lead frame 252 may be combined with one or a plurality of wires toform, for example, a single, double, or triple wire LED illuminationassembly.

Referring to FIGS. 22-24, a double-wire or parallel configuration, LEDillumination assembly 420 that includes lamp 350 with lead frame 252 isdepicted. LED illumination assembly 420 is similar to LED illuminationassembly 166 in configuration, with the exception of the inclusion of adifferent lamp 350, which pierces wires 162 and 164 in a somewhatdifferent manner.

Referring specifically to FIG. 24, when assembled, lead frame 352 topportions 358 and 384 substantially form right angles with wires 162 and164, respectively. More specifically, axis I of top portions 358 and 384forms a right angle with axes L and M of wires 162 and 164.

Unlike LED illumination assembly 166, in this embodiment, namely LEDillumination assembly 420, leads 354 and 356 pierce wires 162 and 164,respectively, at angles other than 90°. As depicted, axis J of topportion 362 forms angle γ with axis L of wire 162, and axis K of topportion 388 forms angle 6 with axis M of wire 164. In the depictedembodiment, angle γ and angle δ are substantially equal, and are eachsubstantially 45°. In other embodiments, angles γ and δ may not beequal, and may be greater than or less than 45°.

Therefore, bottom portions 368 and 394 pierce wires 162 and 164 atangles γ and δ, or 45° in this embodiment. Cutting members 376 and 404cut through insulators 204 and 208, respectively, clasping conductors202 and 208, thereby forming an electrical connection between lead 354and conductor 202, and between lead 356 and conductor 206.

Referring to FIGS. 25 and 26, a single-wire or series configuration, LEDillumination assembly 430 that includes lamp 350 with lead frame 252 isdepicted. In this embodiment, LED illumination assembly 430 includeslamp 350, retaining housing 212, and wire 214. LED illumination assembly430 is similar to LED illumination assembly 210, with the exception oflamp 350 and lead frame 352, and the angle at which lead frame 352interacts with wire 214.

Referring specifically to FIG. 26, in this embodiment, lamp 350, andtherefore lead frame 352, are oriented such that top portions 358 and384 each form a substantially 45° angle with wire 214, while endportions 362 and 368 form substantially 90° degree angles with wire 214.As assembled, cutting members 376 and 404 cut through wire portions 232and 234, respectively, clasping conductors 228 a and 228 b, therebyforming an electrical connection between lead 354 and conductor 228 a,and between lead 356 and conductor 228 b.

One advantage of this embodiment is that because cutting members 376 and404 cut through wire portions 232 and 234 at right angles, a greatercross-sectional area of conductors 228 a and 228 b are in contact withleads 354 and 356, thus potentially improving the electrical connectionbetween lamp 350 and wire 214.

Referring to FIGS. 27 and 28, a triple-wire configuration LEDillumination assembly 440 that includes lamp 350 with lead frame 252 isdepicted. LED illumination assembly 440 is similar to triple-wire LEDillumination assembly 300 described above, with the exception of theinclusion of lamp 350 and lead frame 352, rather than lamp 100 and leadframe 102.

LED illumination assembly 440 includes lamp 350, retaining housing 302,and wires 304, 306, and 308. When assembled, LED illumination assembly440 creates an electrical connection between lead 354 and conductor 338a, and between lead 356 and conductor 338 b, in substantially the samemanner as LED illumination assembly 430 creates an electrical connectionbetween lead frame 352 and wire 214.

Referring to FIGS. 29 to 31, a double wire or parallel configuration,LED illumination assembly 450 that includes lamp 452 with lead frame 454is depicted. LED illumination assembly 450 is similar to LEDillumination assembly 420 in configuration, with the exception of theinclusion of a different lamp 452, which pierces wires 162 and 164 in asomewhat different matter.

Referring to FIG. 29, as with lamp 350, lamp 452 comprises a lead frame454 having a chip carrier 456, a first lead 458 and a second lead 460.First lead 458 includes a lead body 462 having a top portion 464 and anend portion 466 having a first cutting member 468. Second lead 460includes a lead body 470 having a top portion 472 and an end portion 474having a second cutting member 476. As with lamp 350, first and secondleads 458, 460 are operably linked to chip carrier 456 such that leadbodies 462, 470 extend in a generally downward direction from the chipcarrier 456. Lead bodies 462, 470 comprise generally planar shapes,wherein top portions 464, 472 of each lead body 462, 470 isperpendicular to the rest of lead body 462, 470. First cutting member468 further comprises a first cutting blade 468 a and a second cuttingblade 468 b.

First and second cutting blade 468 a, 468 b define a notch 469 betweenblades 468 a, 468 b such that blades 468 a, 468 b may cut through theinsulation 204, 208 of the wires 162, 164 and contact the conductingportion of the wires 202, 206. In some embodiments, no portion theconducting portion of the wires 202, 206 are severed, in otherembodiments, some portion of the conducting portion of the wire issevered, though in any case, leads 458, 460 make electrical contact withthe conduction portion of their respective wires. According to anembodiment of the present invention, notch 469 can comprise a roundedshape conforming to the circular cross-section of the conducting portionof the wire. Second cutting member 476 also further comprises a firstcutting blade 476 a and a second cutting blade 476 b defining a notch477 and arranged in the same manner as first cutting member 468.

Referring also to FIG. 30, lamp 452 can further comprise a lens 482covering chip carrier 456, an LED chip, and a portion of lead bodies462, 470 such that end portions 466, 474 of lead bodies 462, 470protrude from lens 482. Lead bodies 462, 470 cooperatively support lens482 to position the lens 482 over chip carrier 456.

Referring also to FIG. 31, when engaging wires 162 and 164, lead bodies462, 470 of lead frame 454 substantially form right angles with wires162 and 164, respectively. More specifically, axis N of top portions464, 472 form right angles with axes L and M of wires 162, 164.

Unlike LED illumination assembly 420, in lamp 452, leads 458, 460 piercewires 162 and 164, respectively, at right angles similar to LEDillumination assembly 166. However, unlike LED illumination assembly166, first end portion 464 and second end portion 474 a first shoulder478 and a second shoulder 480, respectively, extending outwardly fromleads 468, 468 along axis N. Shoulders 478, 480 allow blades 468 a, 468b, 476 a, 476 b of cutting members 468, 476 to be spaced further apartto accommodate larger gauge wire without increasing the footprint of thetop portions 464, 472 of leads 458, 460. By maintaining the footprint ofthe top portions 464, 472 lead frame 454 can accommodate the same sizelens 482 despite the increased wire gauge. Shoulders 478, 480 can alsoprovide a supporting surface for lens 482 to position lens 482 over chipcarrier 456.

As shown in FIG. 32, an alternate embodiment of lead frame 454 isdepicted. In this alternative embodiment, either first lead 458 orsecond lead 460 can comprise a shoulder 478, 480 while in someembodiments, the opposite lead 458, 460 does not have shoulder 478, 480.Such an embodiment may be used in LED lamp 452 and LED illuminationassembly 450.

Referring again to FIGS. 30 to 31, LED illumination assembly 450 mayfurther comprise a retainer housing 484. Retainer housing 484 canfurther comprise a housing top portion 486 and a housing bottom portion488. Housing top portion 486 defines a recess 490 for receiving LED lamp452 and at least one groove 492 for receiving a wire. Housing bottomportion 488 further comprises at least one groove 494 completing thegroove 492 of top portion 486 and at least two slots 496 for receiving aportion of either blade member 468, 476.

As shown in FIG. 30, housing top portion 486 and housing bottom portion488 can be interlocked around wires 162, 164 such that wires 162, 164are received within grooves 492, 494. LED lamp 452 is insertable throughrecess 490, which guides LED lamp 452 as it engages wires 162, 164 andretains LED lamp 452 after LED lamp 452 is connected to the wires 162,164.

According to an embodiment of the present invention, housing top portion486 can further comprise a locking assembly 495 having locking arms 496extending from the bottom of the housing top portion 486 and having tabs498 for engaging the housing bottom portion 488. Correspondingly, thehousing bottom portion 488 can also define a shoulder 500 for operablyengaging the tabs 498 of the housing top portion 486 to lock the housingtop portion 486 and bottom portion 488 together.

Referring to FIGS. 33 to 34, a single or triple wire configuration LEDillumination assembly 502 that includes a lamp 504 with lead frame 506is depicted. LED illumination assembly 502 is similar to LEDillumination assembly 420 in configuration; with the exception that lamp504 is adapted to pierce only a single wire 563 in either a single ortriple wire configuration.

Referring to FIG. 33, as with lamp 452, lamp 504 comprises a lead frame506 having a chip carrier 508, a first lead 510 and a second lead 512.First lead 510 includes a lead body 514 comprising a top portion 516 andan end portion 518 having a first cutting member 520. Second lead 512includes a lead body 522 having a top portion 524 and an end portion 526having a second cutting member 528. As with lamp 452, first and secondleads 510, 512 are operably linked to chip carrier 508 such that leadbodies 514, 522 extend generally downwardly from chip carrier 508. Leadbodies 514, 522 comprise generally planar shapes, wherein top portions516, 524 of each lead body 514, 522 is perpendicular to the rest of leadbody 514, 522. First cutting member 520 further comprises a firstcutting blade 520 a and a second cutting blade 520 b.

First and second cutting blade 520 a, 520 b define a notch 521 betweenblades 520 a, 520 b such that blades 520 a, 520 b may cut through theinsulation of the wire and contact the conducting portion of the wire563. In some embodiments, the conducting portion of the wire is notsevered, in other embodiments, a portion of the conducting portion ofthe wire is severed, though in any case, leads 458, 460 make electricalcontact with the conduction portion of their respective wires. Accordingto an embodiment of the present invention, notch 521 can comprise arounded shape conforming to the circular cross-section of the conductionportion of the wire. In other embodiments, second cutting member 528also further comprises a first cutting blade 528 a and a second cuttingblade 528 b defining a notch 529 and arranged in the same manner asfirst cutting member 520.

Lamp 504 can further comprise a lens 530 covering chip carrier 508 and aportion of lead bodies 514, 522 such that end portions 518, 526 of leadbodies 514, 522 protrude from lens 530. Lead bodies 514, 522cooperatively support lens 530 to position lens 530 over chip carrier508.

Unlike LED lamp 452, cutting members 520, 528 of lamp 504 are aligned topierce only a single wire 563 at an angle perpendicular to wire 563 incontrast to lamp 452 where cutting members 468, 476 are offset to piercetwo different wires 162, 164 at an angle perpendicular to both wires162, 164.

As depicted in FIG. 34, first and second leads 510, 512 are adapted topierce wire 563 on opposite sides of a gap in wire 230, 336 such thatlamp 504 is connected to wire 563 in series by acting as a bridge acrossthe gap.

Similar to LED illumination assembly 450, LED illumination assembly 502can further comprise a retainer housing 532. Retainer housing 532 canfurther comprise a housing top portion 534 and a housing bottom portion536. Housing top portion 534 defines a recess 538 for receiving LED lamp504 and defines a groove 540. Housing bottom portion 536 furthercomprises a groove 542 completing groove 540 of top portion 534 and atleast two blade slots 537 for receiving a portion of either blade member520, 528.

According to an embodiment of the present invention, retainer housing532 can also comprise a locking assembly 538 similar to locking assembly495 and having locking arms 541 extending from the bottom of housing topportion 534 and having tabs 542 for engaging housing bottom portion 536.Correspondingly, housing bottom portion 536 can also define a shoulder544 for operably engaging tabs 542 of housing top portion 534 to lockhousing top portion 534 and housing bottom portion 536 together.

As shown in FIG. 34, housing top portion 534 and housing bottom portion536 are interlocked around the gap in the wire such that inserting LEDlamp 504 into recess 538 pierces cutting members 520, 528 into ends ofwire 569, 571 on opposite sides of the gap.

However, unlike retention housing 484 in LED illumination assembly 450,retention housing 532 further comprises a divider cap 546 insertableinto retention housing 532 opposite LED lamp 504 according to anembodiment of the present invention. Divider cap 546 comprises a capbody 548 and a wire divider 550. In this configuration, housing bottomportion 536 further comprises a divider slot 552 positioned proximate tothe gap in wire 230, 336. As shown in FIG. 34, wire divider 550 isinserted through divider slot 552 and positioned within the gap betweenthe ends of wire 563 to prevent the ends 569, 571 of wire 563 fromcontacting each other and shorting out LED lamp 504. According to anembodiment of the present invention, wire divider 550 can also comprisea blade member 551 for severing the wire to form the gap.

As depicted, wire 563 may be a single wire of a triple-wire arrangementcomprised of wires 563, 565, and 567, or may be a stand-alone, singlewire 563. Further, a triple-wire arrangement may be a twistedconfiguration as depicted, a triple-parallel arrangement, or otherwise.As such, retainer housing 532 will fit over and retain lamp 504 to wires563, 565, and 567.

Referring to FIG. 35, a top view of assembly 502, is depicted. Lamp 504is retained onto wires 563, 565, and 567 by retainer housing 532, whileLED lead frame 506 is generally parallel to, and piercing, wire 565.

Referring to FIGS. 36 to 38, according to an embodiment of the presentinvention, divider cap 546 can further comprise wire-piercing bypassassembly 552 for preventing the circuit from being electrically brokenin the event lamp 504 or its LED chip 104 fails. Bypass assembly 552comprises a first cutting member 554, a second cutting member 556 and abypass element 558. First cutting member 554 further comprises a firstblade 554 a and a second blade 554 b. Blades 554 a, 554 b are spacedsuch that blades 554 a, 554 b can cut through the insulation of the wireand contact the conducting portion of the wire. Second cutting member556 also further comprises a first cutting blade 556 a and a secondcutting blade 556 b arranged in the same manner as first cutting member554. Selective connecting member 558 operably links first cutting member554 with second cutting member 556 such that current can flow from firstcutting member 554 through bypass element 558 to second cutting member556.

In operation, first cutting member 554 of bypass assembly 552 ispositioned on wire 563 at end 569 proximate to first cutting member 520of lamp 504 while second cutting member 556 of bypass assembly 552 ispositioned proximate to second cutting member 528 of lamp 504 at end 571of wire 563. In other words, first and second cutting members 554, 556of bypass assembly 552 are positioned on either side of the gap in thewire 563 to provide a bypass if the path through lamp 504 is broken by afailed or burned out chip carrier 508. Bypass element 558 may comprise aconsumable resistive coating over a conductive element, a resistor, azener diode or any other conventional means of directing current throughlamp 504 until chip carrier 508 fails or burns out.

According to an embodiment of the present invention, blade slots 536 aresized to receive both cutting members 520, 528 of lamp 504 and cuttingmembers 554, 556 of bypass assembly 552.

Referring to FIGS. 39 to 44, a triple wire configuration, an alternativeLED illumination assembly 559 for lamp 504 with lead frame 506 isdepicted. LED illumination assembly 559 is similar to LED illuminationassembly 502 in configuration, with the exception that LED illuminationassembly 559 further comprises a retention housing 560 having a jumperassembly 562 for operably linking a primary wire 563 pierced by lamp 504with a secondary wire 565. Secondary wire 565 can comprise the groundwire or return loop of the primary wire 563.

As depicted in FIGS. 39 and 40, LED illumination assembly 558 comprisesa retainer housing 560 for receiving lamp 504. Retainer housing 560 cancomprise a housing top portion 564 and a housing bottom portion 566.Housing top portion 564 further comprises a recess 568 for receiving LEDlamp 504 and defines a primary groove 570 and at least one secondarygroove 572. Housing bottom portion 566 further comprises a primarygroove 574 complementing primary groove 570 of housing top portion 564and a secondary groove 576 complementing each secondary groove 572 ofhousing top portion 564. Housing bottom portion 566 also comprises atleast one blade slot 578 for receiving a portion of either blade member520, 528.

As with retainer housing 532, retainer housing 560 can also comprise alocking assembly 580 having locking arms 582 extending from the bottomof housing top portion 564 and having tabs 584 for engaging housingbottom portion 566. Correspondingly, housing bottom portion 566 can alsodefine a shoulder 586 for operably engaging tabs 584 of housing topportion 564 to lock housing top portion 564 and housing bottom portion566 together.

As shown in FIG. 39, housing top portion 564 and housing bottom portion566 are interlocked around a gap in the primary wire such that insertingLED lamp 504 into recess 568 forces cutting members 520, 528 into endsof primary wire 536 on opposite sides of the gap in primary wire 536.

As with retainer housing 532, retainer housing 560 can also comprise adivider cap 588 insertable into retention housing 560 opposite LED lamp504 according to an embodiment of the present invention. Divider cap 588comprises a cap body 590, a wire divider 592, and positioning andoptional tab 593. In this configuration, housing bottom portion 536further comprises a divider slot 594 positioned proximate to the gap inprimary wire 536. Alternatively, blade slot 578 can be sized to receiveboth wire divider 592 and blade member 520, 528. As shown in FIG. 39,wire divider 592 is inserted through divider slot 594 and positionedwithin the gap in primary wire 563 to prevent the ends of primary wire563 for contacting each other and shorting out LED lamp 504.

In an embodiment that includes tab 593, wire 563 may be terminated atlead 520 of LED lamp 504. Such an embodiment may be useful forconstructing a decorative light string, as discussed further below withrespect to FIGS. 54 a to 56. In such an embodiment, illuminationassembly 559 includes tab 593, wire portion 563 a, but does not includewire portion 563 b. Tab 593 extends upwardly into divider slot 594,blocking off the right-side entrance to the wire grooves (alternativelycapable of receiving wire portion 563 b). Blocking entry to illuminationassembly 559 through the grooves prevents an external object fromentering illumination assembly 559 and contacting electrified componentswithin the assembly.

In yet another embodiment, tab 593 may not be present, and both wireportions 563 a and 563 b may be used.

Specifically referring to FIGS. 40 to 43, retainer housing 560 furthercomprises a jumper assembly 562 operably linking primary wire 563 tosecondary wire 567 (as depicted), or in an alternate position, linkingwire 563 to wire 565. Jumper assembly 562 comprises a blade wall 577 anda connecting wall 579. As depicted, blade wall 577 forms anapproximately right angle with connecting wall 579.

Blade wall 577 further comprises a first cutting blade 577 a and asecond cutting blade 577 b defining a notch 568 between cutting blades577 a, 577 b such that cutting blades 577 a, 577 b can cut through theinsulation of the secondary wire 567 and contact the conducting portionof the wire 567 without severing the conduction portion. According to anembodiment of the present invention, notch 568 can comprise a roundedshape conforming to the circular cross-section of the conduction portionof the secondary wire 565.

When assembled, in addition to blade wall 577 piercing and connecting towire 567, connecting wall 579 along its surface contacts at least aportion of lead frame 502 at lead 528 to form an electrical connectionbetween wire 567 and lead 528. Such an electrical connection may be usedwhen assembly 559 forms a portion of a decorative light set, such aswhen assembly 559 comprises a last LED lamp 504 in a series of LEDlamps.

An embodiment of a resulting electrical connection is depicted in FIG.44 a, which includes both wire portions 563 a and 563 b. FIG. 44 bdepicts an alternate embodiment that terminates wire 563 at assembly559, such that only wire portion 563 a is used, and wire portion 563 bis not.

Further, it will be understood that LED lamp 504 may be oriented asshown, with the LED cathode electrically connected to jumper 562 andwire 567, or alternately, with the LED anode electrically connected tojumper 562 and wire 567. It will also be understood that a jumper 562may connect LED lamp 504 to wire 565, rather than wire 567.

Referring to FIGS. 45 and 46, an alternate embodiment of assembly 559,illumination assembly 561, is depicted. Illumination assembly 561 issubstantially the same as the embodiment of assembly 559 depicted anddescribed above, except that assembly 561 of FIGS. 45 and 46 includesthe bypass feature described above with respect to FIGS. 36-38. In thisarrangement, assembly 561 includes both a jumper to connect wires 563and 567, and a bypass 558 around LED chip 104.

Referring to FIG. 47, an LED lamp 598 having a lead frame 600 for use insingle or triple wire configurations is depicted. LED lamp 598 issimilar to LED lamp 504; with the exception that LED lamp 598 a twistedfirst lead 602 and a twisted second lead 604.

Lamp 598 comprises a lead frame 600 having a chip 606, a first lead 602,and a second lead 604. First lead 602 includes a lead body 608comprising a top portion 610 and an end portion 612 having first cuttingmember 614. Second lead 604 includes a lead body 616 comprising a topportion 618 and an end portion 620 having a second cutting member 622.As with lamp 504, first and second leads 602, 604 are operably linked tochip 606 such that lead bodies 608, 616 extend generally downward fromchip 606.

First and second leads 602, 604 comprise a wishbone shape having a wide,planar top portion 610, 618 and wide, end potion 612, 620 linked by anarrow center. Unlike lamp 504, end portions 612, 620 of first andsecond leads 602, 604 are twisted relative to top portions 610, 618 suchthat end portion 612, 620 and top portion 610, 618 of each lead 602, 604are perpendicular to each other.

In general, lead frame 600 and lamp 598 may be interchanged with leadframes or lamps having leads in two different planes similar to thosedescribed above, including, for example, lead frame 454 and lamp 452.However, lead frame 600 may provide manufacturing process advantagesover non-twisted lead frames.

More specifically, lead frame 600 may initially be stamped in a planarconfiguration out of a planar piece of lead frame material, followed bytwisting of leads 602 and 604.

Referring to FIGS. 48 a to 48 c, another embodiment of an LED leadframe, lead frame 700 is depicted. LED lead frame 700 is alsomanufactured in a planar configuration of a planar piece of lead-framematerial. FIG. 48 a depicts several lead frames 700 still attached tolead-frame carrier 702, prior to separation of the lead frames 700 fromcarrier 702. FIG. 48 b depicts a left-side view of lead frames 700connected to lead-frame carrier 702, and FIG. 48 c depicts a top view oflead of lead frames 700 connected to lead frame carrier 702.

As depicted, each lead frame 700 includes first lead 704, second lead706, and chip carrier 708. In an embodiment, chip carrier 708 isintegral to second lead 706, while in other embodiments, chip carrier708 is added as a separate component to second lead 706. Each of firstlead 704 and second lead 706 includes a first pair 710 of cuttingmembers 712, a second pair 714 of cutting members 712, and forms ashoulder 716. For any particular lead frame 700, first and second leads704 and 706 are generally coplanar. All cutting members 712 aregenerally coplanar to one another, as are pairs 710 and 716. The firstand second wire-receiving channels each define a V-shaped opening at abottom end and an arcuate portion at a top end. A top surface of lead706 that carries chip carrier 708, and an LED chip, such as a chip 104(not depicted in FIG. 48, refer generally to FIGS. 1-4), defines agenerally horizontal plane that is generally perpendicular to the planeformed by the leads 704, 706, and the cutting members 712. When mountedto chip carrier 708 and second lead 706, a portion of LED chip 104 maybe intersected by the lead plane.

First lead 704 may be relative narrow at a top portion, then widen at abottom portion adjacent pair 710 of cutting members 712. Second lead 706may be relatively wide at a top portion for the purpose of carrying chipcarrier 708, have a relatively narrow middle portion, then widen againat a bottom portion adjacent pair 714 of cutting members 712. Leads 704and 706 may also include a series of bends and recesses. Such bends andrecesses may be in part a result of material saving methods, but alsomay coincide with a bottom surface of an encapsulating lens or otherhousing structures in a lamp or lighting assembly (not depicted in FIG.48) that includes lead frame 700.

During the manufacturing process, lead frame carrier 702 may begin as agenerally rectangular, continuous strip of relatively thin conductingmaterial. Portions of lead-frame carrier 702 are stamped or punched outleaving lead frames 700 attached to lead-frame carrier 702 at multiplepoints 720. Individual lead frames 700 may be cut, bent to break, orotherwise removed from lead-frame carrier 702. Prior to removal fromlead-frame carrier 702, additional processing to lead frames 700 may becarried out. Such processing may include adding an LED chip, such as achip 104, an encapsulating lens, such as a lens 108, or even a housing106. The addition of a lens 108 over a portion of each of leads 704 and706 keeps the lead positions fixed relative to one another when removedfrom lead-frame carrier 702.

Referring to FIGS. 49 to 50 c, an embodiment of lighting assembly 730that includes an embodiment of lead frame 700 is depicted. FIG. 49depicts an exploded view of lighting assembly 730, FIG. 50 a depicts afront view of lighting assembly 730 as fully assembled, though withoutwires, FIG. 50 b depicts a top view of assembly 730, and FIG. 50 cdepicts a front, cross-sectional view of lighting assembly 730.

Lighting assembly 730 includes LED lamp 732, housing top portion 734,retainer 736, and housing bottom portion 738. Lighting assembly 730 mayalso include lamp cover 740, as depicted.

LED lamp assembly 732 includes parallel-lead-type lead frame 700, lens741, and an LED chip 104 (not depicted). Lead frame 700 includes firstlead 704 and second lead 706.

Housing top portion 734 includes a generally cylindrical body portion742 and lower portion 744. Cylindrical body portion 742 defines centralrecess 744, front, planar surface 745, rear planar surface 746, and apair of horizontal surfaces 747 at the base of surfaces 745 and 746. Asexplained further below, recess 744 may be generally cylindrical at atop portion, and wider with flat sides at a bottom portion to receiveretainer 736. Lower portion 744 may be integral to body portion 742 andincludes left shoulder 748, right shoulder 750, front tab 752, and reartab 754. Left shoulder 748 and right shoulder 70 each form a horizontaltop surface, and downward, and inward angling side surfaces.

Retainer 736 includes a generally cylindrical upper portion 754extending upward and away from lower portion 756. Upper portion 754defines one or more lead-frame receiving slots 758. Lower portion 756 asdepicted includes arcuate left and right sides 760 and 762,respectively, and generally flat front and rear sides 764 and 766,respectively. Lower portion 756 also defines a generally flat bottomsurface 768.

Housing bottom portion 738 includes generally vertical left and rightside walls 770 and 772, respectively. Housing bottom portion 738 alsodefines left shoulder-receiving recess 774, right shoulder-receivingrecess 776, bottom surface 778, and wire-channels 780. Housing bottomportion 738 in an embodiment may also define recess 782 which receivestips of each of cutting members 712 that may extend through the wires(not depicted) when assembled. FIG. 52 b also depicts recess 782. Adistance from an inside surface of the left wall 770 to an insidesurface of the second wall 772 in an embodiment is less than a distancefrom a leftmost portion of left shoulder 748 to a rightmost portion ofright shoulder 750.

When assembled, LED lamp 732 fits into the upper portion of recess 744.As depicted in FIG. 50 c, a portion of LED lamp 732, including lens 741may extend above and outside housing top portion 734. First and secondleads 704 and 706 project downward into recess 744, and into slots 758or retainer 754. In an embodiment, retainer 754 may define a single slot758 to receive leads 704 and 706, or a pair of slots 758, one each toreceive lead 704 and 706.

Retainer 736 is inserted upwardly into a bottom portion of recess 744. Abottom of lens 741 may seat against a top of retainer 754 when fullyinserted into housing top portion 734 and retainer 736. The bottomportion of recess 744 includes a pair of generally flat surfaces thatare adjacent front and back sides 764 and 766 to for a type of keyedfitting, such that retainer 736 does not rotate when inserted intohousing top portion 734. In an embodiment, retainer 754 is fullyreceived by housing top portion 734 such that bottom surface 768 iscoplanar with a bottom surface of housing top portion 734.

Housing top portion 734 with retainer 736 is inserted into housingbottom portion 738. Although not depicted in FIGS. 49 to 50 a, it willbe understood that a pair of wires as described above, will be receivedby grooves or wire channels 780, and held securely in place when housingtop portion 734 is fitted to housing bottom portion 738, similar to thehousing and wire embodiments described above. Flat front and rear sidesof top portion 734 may be used to hold and position top portion 734relative to bottom portion 738 during assembly. Front and rear tabs 752and 754 extend frontwardly and rearwardly, respectively, adjacent topsurfaces of the wires.

As housing top portion 734 is forced downward into housing bottomportion 738, left side 770 and right side 772 bend or flex outwardly(away from center) to allow left shoulder 748 to align with, and bereceived by, left recess 774, right shoulder 750 to be aligned with andreceived by, right recess 776. The receiving of shoulders 748 and 750into their respective recesses 774 and 776 forms a tight fit betweenhousing top portion 734 and housing bottom portion 738.

When top portion 734 is fit to bottom portion 738, bottom surface 768and portions of the bottom surface of housing top portion 734 areadjacent the wires and top surface 778 of housing bottom portion 738,and apply a downward force to the wires and to top surface 778. Anassembly force may be applied at horizontal surfaces 747 of top portion734 to bring portions 734 and 738 together during assembly.

Cutting members 712 pierce the wires as described above with respect toother embodiments of the invention, when LED lamp 732 is fully insertedinto housing top portion 734, retainer 736, and housing bottom portion738.

Lamp cover 740, when used, is inserted over lens 741 and into the topportion of recess 744. Lamp cover 740 may be held in place through afriction fit comprising lamp cover 740, lens 741, and housing topportion 734, or alternatively, may be held by other means, including anadhesive.

Consequently, when LED lamp 732, housing top portion 734, retainer 736,and housing bottom portion 738 are assembled on to a pair of wires toform lighting assembly 730, assembly 730 aligns the cutting members 712such that they can form the proper electrical connection by piercingconductors of the wires, and securely hold the various components snuglyand safely together using any combination of friction, compression andsnap fitments.

Referring to FIGS. 51 a and 51 b, an alternative embodiment of lightingassembly 730 is depicted. The depicted embodiment of lighting assembly730 is substantially the same as the embodiment depicted in FIGS. 48 to50 c, with the addition of clip 784.

Clip 784 in an embodiment is connected to, and adjacent either of leftside 770 or right side 772 of housing lower portion 738. In anembodiment, clip 784 is integral to housing lower portion 738.

Clip 784 includes first arm 786 and second arm 788. First and secondarms 786 and 788 are generally arcuate, forming a C-shape and opening790. Opening 790 may be sized to receive a portion of a branch of anartificial tree such that clip 784 may be used to attach lightingassembly 730 to the branch of an artificial tree, thereby forming alighted artificial tree.

Distal ends 792 and 794 of arms 786 and 788, respectively, may projectaway from one another to form branch guide 796. When a portion of abranch of an artificial tree is inserted into branch guide 796, andforced towards opening 790, arms 786 and 788 may flex apart, allowingthe portion of the branch to fit into opening 790, thusly securinglighting assembly 730 to the branch.

Referring to FIGS. 52 a and 52 b, another embodiment of a lightingassembly 730 having clips 800 and 802 is depicted. In this embodiment,clips 800 and 802 are sized to secure lighting assembly 730 to wires orwire-like strands to form a decorative net light.

Clip 800 includes arm 804 extending outwardly and away from housingbottom portion 738, and curved arm 806 which also extends outwardly andaway from portion 738, and then towards arm 804. Arms 804 and 806 definean opening 808 for receiving the wires or the wire-like strands. Arms804 and 806 also define a gap, through which the wires may pass. Clip802 is substantially the same as clip 800.

Referring to FIGS. 53 a to 53 c, an alternate lighting assembly 900 isdepicted. This embodiment is similar to lighting assembly 730 asdescribed above with respect to FIGS. 48 to 52 c. Rather than a separatehousing top portion and retainer, lighting assembly 900 includes anintegrated housing-retainer 902.

Lighting assembly 900 includes an LED lamp, such as lamp 732,housing-retainer 902, and housing bottom portion 738. In an embodiment,housing-retainer 902 is directly molded onto LED lamp 732. Lens 741 mayalso be molded onto lead frame 700 to encapsulate an LED chip andportions of lead frame 700, followed by over-molding housing-retainer902 onto lens 741 and the remainder of LED lamp 732 to form lamp-housingassembly 904.

Lamp-housing assembly 904 may then be connected to housing bottomportion 738 by forcing assembly 904 downwards onto bottom portion 738,causing shoulders 748 and 750 to clip into their respective recesses,and causing members 712 to pierce their respective wires (not depicted),similar to the embodiment described above with respect to FIGS. 48-52 c.

Referring to FIGS. 54 a to 56, any combination of the above-describedillumination assemblies may be used to construct a decorative lightstring.

Referring specifically to FIGS. 54 a to 54 e, block diagrams depictingelectrical schematics of various embodiments of the illuminationassemblies described above are depicted.

FIG. 54 a depicts an electrical schematic of a two-wire illuminationassembly 166. This electrical schematic also applies equally toillumination assemblies 420, 452, 450, 730, and 900, though for the sakeof description, an illumination assembly 166 will be discussed. Two-wireillumination assemblies, such as illumination assembly 166, may be usedin the construction of a parallel configured decorative light string.

FIG. 54 b depicts a single-wire illumination assembly 210. Such asingle-wire illumination assembly may be used in a series orseries-parallel decorative light string.

FIGS. 54 c, 54 d, and 54 e depict three-wire illumination assemblies300, 559 a, and 559 b, respectively. Illumination assemblies 559 a and559 b each include a jumper 577, as described above with respect toFIGS. 40 to 44. Three-wire illumination assemblies may be used in theconstruction of series-parallel decorative light strings which may ormay not include an end connector for providing power at an end of thelight string opposite the power plug.

Referring to FIG. 55, a parallel-configured decorative light string 910is depicted. Light string 910 includes an optional power plug 912,optional power connector 914, and a plurality of parallel connected,two-wire, illumination assemblies 166 electrically connected in parallelby a pair of wires 922 and 924. Decorative light string 910 may alsoinclude an optional power converter 926.

Power plug 912 receives power from an external power source (notdepicted), and provides power to LEDs 104 such that they emit light.Power connector 914, sometimes referred to as an “end connector”, may beused to provide power to a second light string.

In an embodiment for general use, and for some artificial lighted trees,light string 910 includes power plug 912 and power converter 926. Powerplug 912 may be plugged into a wall outlet to receive AC power, such as120VAC. Power converter 926 may convert or transform the received 120VACvoltage to a lower DC voltage, for example, 3VDC for use with LEDs 104rated for 3VDC.

In an embodiment for use with an artificial tree, light string 910 maynot include power plug 912, may not include power connector 914, and maybe directly connected to bus or power lines of the artificial tree.

Traditional decorative light strings that do not use wire-piercing lampstypically include a number of short wire segments, each end of the wiresegment terminating with a crimped-on terminal for making an electricalconnection with a bulb within a socket. Such traditional sets requiresignificant assembly time, and are prone to loose connections which maylater cause arcing and present a safety hazard.

Unlike such traditional light sets, light set 910 includes twocontinuous wires 922 and 924 extending from one end of the light set tothe other end. Each wire is pierced at multiple points to makeelectrical connections to illumination assemblies 166, but otherwise arecontinuous, thus decreasing assembly effort and avoiding connection andother issues associated with traditional light sets. In otherembodiments, wires 922 and 924 may be comprise some wire breaks.

Other embodiments of light string 910 may substitute other embodimentsof illumination assemblies, including illumination assemblies 420, 452,450, 730, and 900 as described above, in addition to, or rather than,illumination assembly 166.

Referring to FIG. 56, an embodiment of a series-parallel-configuredlight string 920 is depicted. Light string 920 includes optional powerplug 912, power connector 914, first series-connected light group 928,second series-connected light group 930, and continuous wires 932, 934,936, and 938.

First light group 928 includes a plurality of illumination assemblieshaving LEDs electrically connected in series, including illuminationassemblies 559 b, 300 and 559 a. Illumination assemblies 559 a and 559 bare three-wire assemblies, while assemblies 300 are two-wire assemblies.

Second light group 930 includes a plurality of illumination assemblieshaving LEDs electrically connected in series, including illuminationassemblies 559 b, 210 and 559 a. Illumination assemblies 559 a and 559 bare three-wire assemblies, while assemblies 210 are single-wireassemblies. Single-wire illumination assemblies 210 could beinterchanged with two-wire assemblies 300, but for the sake ofillustration, second light group 930 includes assemblies that vary fromfirst light group 928.

Wire 932 is continuous from a power plug end of light string 920 to thepower connector end, providing power to the first LED of each lightgroup 928 and 930. Wire 930 is also continuous from the power plug endto the power connector end, connected to each last LED in each lightgroup 928 and 930, thereby providing an electrical return path for eachlight group. Wire 936 connects each LED in series in first light group928, while wire 938 connects each LED in series in second light group930. Wires 936 and 938 define a series of gaps within the illuminationassemblies, and bridged by LED lamps, as described above with respect toillumination assemblies 166.

The LEDs of light group 928 are electrically connected in series, as arethe LEDs of light group 930. Light group 928 is electrically connectedin parallel with light group 930. Although only four illuminationassemblies for each light group 928 and 930 are depicted, it will beunderstood that a larger or smaller number of illumination assemblies,and hence LEDs, may comprise a light group.

In an embodiment, light string 920 is powered by a 120VAC power source,and includes two light groups 928 and 930. Each light group 928 and 930includes 50 illumination assemblies, or 50 LEDs, each LED receivingapproximately 2.4VAC.

In another embodiment, light string 920 is powered by a 120VAC powersource converted to 12VDC, and includes ten light groups. Each lightgroup includes four LEDs rated at 3VDC.

It will be understood that any combination of wire-piercing illuminationassemblies with wire-piercing LED lead frames may be used to constructvarious parallel, series, series-parallel, and parallel seriesdecorative light strings according to embodiments of the presentinvention.

Although the present invention has been described with respect to thevarious embodiments, it will be understood that numerous insubstantialchanges in configuration, arrangement or appearance of the elements ofthe present invention can be made without departing from the intendedscope of the present invention. Accordingly, it is intended that thescope of the present invention be determined by the claims as set forth.For purposes of interpreting the claims for the present invention, it isexpressly intended that the provisions of Section 112, sixth paragraphof 35 U.S.C. are not to be invoked unless the specific terms “means for”or “step for” are recited in a claim.

1. A light-emitting diode (LED) illumination assembly, comprising: aretention housing including a top portion coupled to a bottom portion,the top portion defining an LED lamp-receiving recess; an LED lampincluding a wire-piercing LED lead frame having first and second leads,the LED lamp inserted into the LED lamp-receiving recess of the topportion; a first wire including a conductor and an insulator, and asecond wire including a conductor and an insulator, at least a portionof each of the first wire and the second wire located between the topportion and the bottom portion of the retention housing; and wherein thefirst lead of the LED lead frame pierces at least a portion of the firstinsulator and the second lead of the LED lead frame pierces at least aportion of the second insulator, such that the first LED lead contactsthe conductor of the first wire and the second LED lead contacts theconductor of the second wire.
 2. The LED illumination assembly of claim1, wherein the wire-piercing LED lead frame further includes a firsttransition portion for contacting the first wire and limiting the travelof the LED lamp.
 3. The LED illumination assembly of claim 1, whereinthe wire-piercing LED lead frame further includes a second transitionportion for contacting the second wire and limiting the travel of theLED lamp.
 4. The LED illumination assembly of claim 1, wherein the firstlead and the second lead are separated by a frontward to rearwardoffset.
 5. The LED illumination assembly of claim 1, wherein theportions of the first wire and the second wire located between the topportion and the bottom portion of the retention housing lie alongsubstantially the same axis.
 6. The LED illumination assembly of claim 3wherein the retention housing further includes a wire divider locatedbetween the first wire and the second wire.
 7. The LED illuminationassembly of claim 5, wherein the LED lead frame is substantiallyperpendicular to the first and the second wire.
 8. The LED illuminationassembly of claim 5, wherein the portions of the first wire and thesecond wire located between the top portion and the bottom portion ofthe retention housing lie in separate, parallel axes, such that theportions of the first wire and the second wire are adjacent to eachother.
 9. The LED illumination assembly of claim 1, further comprising athird wire having a third conductor and a third insulator.
 10. The LEDillumination assembly of claim 9, wherein the lead frame does not piercethe third conductor.
 11. A single-wire light-emitting diode (LED)illumination assembly, comprising: a housing defining an LEDlamp-receiving recess; an LED lamp including a wire-piercing LED leadframe having a first lead with a first cutting member defining a firstplane and a second lead with a second cutting member defining a secondplane, the LED lamp inserted into the LED lamp-receiving recess of thetop portion; a wire including a forward portion and a rear portion, atleast a portion of the wire retained by the housing, the first wiredefining a gap between the forward portion and the rear portion; andwherein the first lead of the LED lead frame pierces an insulator of theforward portion of the wire and contacts a conductor of the forwardportion, and the second lead of the LED lead frame pierces an insulatorof the rear portion of the wire and contacts a conductor of the rearportion, such that the forward portion of the wire is electricallyconnected to the rearward portion of the wire through the LED lamp. 12.The LED illumination assembly of claim 11, wherein the first plane andthe second plane define parallel planes.
 13. The LED illuminationassembly of claim 12, wherein the first cutting member pierces theforward portion of the wire perpendicular to an axis defined by thelength of the wire, and the second cutting member pierces the rearportion of the wire perpendicular to the axis.
 14. The LED illuminationassembly of claim 12, wherein the first cutting member pierces theforward portion of the wire at an angle of 45 degrees with respect to anaxis defined by the length of the wire, and the second cutting memberpierces the rear portion of the wire at an angle of approximately 45degrees with respect to the axis.
 15. The LED illumination assembly ofclaim 11, wherein the first plane and the second plane define the sameplane.
 16. The illumination assembly of claim 11, wherein the housingincludes a top portion coupled to a bottom portion, the top portion andthe bottom portion each defining a groove for receiving the wire. 17.The illumination assembly of claim 16, wherein the bottom portionfurther comprises a wire divider projecting upwards and away from thebottom portion and into the gap between the forward portion and therearward portion of the wire.
 18. The illumination assembly of claim 17,wherein the wire divider comprises a non-conductive material.
 19. Alight-emitting diode (LED) illumination assembly, comprising: an LEDlamp including a lead frame having a first wire-piercing lead with afirst cutting member and a second wire-piercing lead with a secondcutting member; a housing defining a central recess and a wire channel;and a retainer inserted into a bottom portion of the central recess ofthe housing; wherein the LED lamp is inserted into a top portion of thecentral recess of the housing and into contact with the retainer suchthat the first and second cutting members extend into the wire channel.20. The LED illumination assembly of claim 19, further comprising afirst wire in the wire channel, the first cutting member piercing thefirst wire to make electrical contact with a conductor of the firstwire.
 21. The LED illumination assembly of claim 20, further comprisinga second wire in the wire channel, the second cutting member piercingthe second wire to make electrical contact with a conductor of thesecond wire.
 22. The LED illumination assembly of claim 19, wherein thehousing comprises a top portion coupled to a bottom portion.
 23. The LEDillumination assembly of claim 22, wherein the top portion includes afirst shoulder projection and a second shoulder projection, the bottomportion defines a left recess and a right recess, the left recessreceiving the left shoulder and the right recess receiving the rightshoulder, thereby coupling the top portion to the bottom portion. 24.The LED illumination assembly of claim 19, wherein the retainer definesa slot, and the slot receives a portion of the first and second leads,thereby retaining and orienting the LED lamp in the housing.
 25. The LEDillumination assembly of claim 19, further comprising a bulb coverplaced over a top portion of the LED lamp, a portion of the bulb coverextending into the housing.
 26. The LED illumination assembly of claim19, further comprising a branch clip attached to the housing.
 27. TheLED illumination assembly of claim 26, wherein the branch clip comprisesa first arm and a second arm forming a C shape.
 28. The LED illuminationassembly of claim 19, further comprising a pair of wire clips attachedto the housing.
 29. The LED illumination assembly of claim 28, each wireclip including a first straight arm extending away from the housing, anda second curved or angled arm, the first and second arm defining anopening sized to receive a wire.